Process for encapsulating fragile insulation materials within polyisocyanurate

ABSTRACT

Embodiments of the present invention are based, at least in part, on the discovery of methods for encapsulating fragile insulation materials within polyisocyanurate foam to thereby provide a construction board having an advantageous balance of insulating properties and mechanical durability.

This application claims the benefit of U.S. Provisional Application Ser.No. 61/972,737, filed on Mar. 31, 2014, which is incorporated herein byreference.

FIELD OF THE INVENTION

Embodiments of the present invention are directed toward processes forencapsulating fragile insulation materials within polyurethane orpolyisocyanurate foam. Embodiments of the present inventionadvantageously take advantage of continuous processing techniques.

BACKGROUND OF THE INVENTION

Fragile insulation materials are known in the art and include materialssuch as vacuum insulation panels. While these materials provideadvantageous insulating properties, they often have weak mechanicalattributes. For example, fragile insulation materials, such as vacuuminsulation panels, are often manufactured from very friable materials,such as fumed silica, aerogel, perlite, or glass. As a result, thesematerials are susceptible to mechanical damage during use. Additionally,vacuum insulation panels rely on gas-tight enclosures to ensure propervacuum, which provides the insulating capability to the material. Wherethis enclosure is compromised, such as through puncture, the insulatingcapabilities of the material are diminished or lost.

Attempts have been made at providing composites wherein fragileinsulation materials (e.g., VIPs) are provided within a composite. Forexample, WO2006/134581 proposes an insulating panel wherein a VIP isembedded into a foam during manufacture of the panel. This manufacturingprocess includes the laying down of a first foam layer, followed by thepositioning of a VIP onto the foam, and then the second laying down offoam over the VIP.

Methods, such as those proposed by WO2006/134581, suffer from apparentproblems associated with the ability to properly position the VIP ontothe foam layer. Efforts to solve these problems are shown in U.S.Publication No. 2013/0089696, wherein VIPs are adhesively secured to afacer material prior to the application of the foam material. The use ofthe adhesive enables accurate and stable positioning of the VIPs duringthe manufacturing process. This accurate positioning allows minimal gapsbetween the VIPs thereby reducing edge losses and allowing bettertolerance for cutting final panel sizes.

While adhesively securing the VIPs to a facer may provide advantage withrespect to the accurate and stable positioning of the VIP, a problemremains in that the VIP is not completely encased within, and thereforenot completely protected by, the foam layer.

Since fragile insulation materials, such as vacuum insulation panels,offer advantageous insulating properties, their use as insulatingmaterials within the construction industry would be highly advantageous.This usefulness, however, is contingent upon the ability to protectthese materials from various mechanical forces. Moreover, the successfuluse of these boards within the construction industry will be contingenton the ability to develop continuous manufacturing processes that canefficiently and cost effectively produce commercial product.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematical representation of a process according toembodiments of the present invention.

FIG. 2 is an overhead view of a pattern for placing fragile insulationmaterials according to embodiments of the present invention.

FIG. 3 is a schematical representation of a process according toembodiments of the present invention.

FIG. 4 is a cross-sectional, side view showing a step according to aprocess according to embodiments of the invention.

FIG. 5 is a schematical representation of a process according toembodiments of the present invention.

SUMMARY OF THE INVENTION

One or more embodiments of the present invention provides a process forencapsulating fragile insulation materials, the process comprisingproviding a preformed construction board, positioning one or morefragile insulation materials on the board, and depositing a developingfoam over the fragile insulation materials to at least partially coverthe fragile insulation materials and at least partially mate thedeveloping foam with the construction board

One or more embodiments of the present invention provides a process forencapsulating fragile insulation materials, the process comprising,providing a facer material, depositing a developing foam on to the facermaterial, positioning one or more fragile insulation materials on to thedeveloping foam, depositing additional developing foam over the fragileinsulation materials to at least partially cover the fragile insulationmaterials and mate with the previously deposited developing foam.

One or more embodiments of the present invention provides a process forencapsulating fragile insulation materials, the process comprising,providing a facer material, positioning one or more spacers on the facermaterial, positioning one or more fragile insulation materials on to thespacers, depositing a developing foam on to the fragile insulationmaterials and the facer.

DETAILED DESCRIPTION OF ILLUSTRATIVE EMBODIMENTS

Embodiments of the present invention are based, at least in part, on thediscovery of methods for encapsulating fragile insulation materialswithin polyisocyanurate foam to thereby provide a construction boardhaving an advantageous balance of insulating properties and mechanicaldurability. According to one or more of the embodiments of thisinvention, encapsulation of the fragile insulation material takes placeby depositing a developing foam of polyurethane or polyisocyanurate onone or more surfaces of a fragile insulation material to provide acomposite wherein the fragile insulation material is completelyencapsulated by the foam. These methods advantageously employconventional equipment that is used for producing polyurethane orpolyisocyanurate construction board, such as conventional foamapplicators and laminator systems.

Fragile Insulation Materials

Practice of the present invention is not necessarily limited by theselection of the fragile insulation material that is encapsulated by theprocesses described herein. In one or more embodiments, the fragileinsulation materials offer greater insulating properties than thepolyurethane or polyisocyanurate foams that encase them. In one or moreembodiments, the fragile insulation materials have a lower thermalconductivity than the polyurethane or polyisocyanurate foams that encasethem. In one or more embodiments, the fragile insulation materialsinclude a friable component.

In one or more embodiments, the fragile insulation materials are orinclude cellular or open cell structures wherein the cellular walls ofthe cellular structure include one or more of silica (e.g., fumed orprecipitated silica), alumina, titania, magnesia, chromia, tin dioxide,glass wool, fiberglass, and carbon. In one or more embodiments, thecellular structure my include aluminosilicates such as, but not limitedto, perlite.

In one or more embodiments, the fragile insulation material may includean aerogel. Specific examples include carbon aerogels, silica aerogels,and alumina aerogels.

In one or more embodiments, the fragile insulation material includes avacuum insulation panel (VIP). Vacuum insulation panels are known andgenerally include substantially gas-tight enclosures surrounding a rigidcore wherein air therein has been evacuated. The enclosures may includemembrane walls that prevent air from entering the panel. The core mayinclude a rigid, highly-porous material that supports the membrane wallsagainst atmospheric pressure once the air is evacuated.

Examples of vacuum insulation panels include those that include acellular core that may include silica (e.g., fumed or precipitatedsilica), alumina, titania, magnesia, chromia, tin dioxide, glass wool,fiberglass, carbon, aluminosilicates (e.g., perlite), open-cellpolystyrene, or open cell polyurethane. In these or other embodiments,the core may include an aerogel such as carbon aerogels, silicaaerogels, and alumina aerogels.

Some specific examples of vacuum insulation panels are also described inU.S. Pat. Publ. Nos. 2013/0216854, 2013/0216791, 2013/0142972,2013/0139948, 2012/0009376, 2009/0126600, 2008/0236052, 2004/0058119,2003/0159404, and 2003/0082357 which are incorporated herein byreference.

Other thermal insulation products include those that can be employed asthe fragile insulation materials within this invention include modifiedatmospheric insulation (MAI) panels. Devices of this nature, and methodsfor their manufacture, are disclosed in U.S. Publication Nos.2014/0360044 and 2014/0366480, which are incorporated herein byreference.

Developing Foam

Throughout this specification, reference may be made to a developingfoam. This term is used with the understanding that polyurethane andpolyisocyanurate foams (which terms may generally be usedinterchangeably herein as described below) are formed by mixing a firststream that includes an isocyanate-containing compound with a secondstream that includes an isocyanate-reactive compound. Using conventionalterminology, the first stream (i.e., the stream including anisocyanate-containing compound) may be referred to as an A-side stream,an A-side reactant stream, or simply an A stream. Likewise, the secondstream (i.e., the stream including an isocyanate-reactive compound) maybe referred to as a B-side stream, B-side reactant stream, or simply Bstream. In any event, the reaction that ensues produces a foam that,according to one or more kinetic and/or thermodynamic properties,develops over a period of time. Unless otherwise specified, therefore,the term developing foam will be understood to refer to the mixture ofthe polyurethane and/or polyisocyanurate reactants as they exist priorto cure, which when the reaction mixture is appreciably immobile (e.g.is no longer flowable).

In one or more embodiments, either stream may carry additionalingredients including, but not limited to, flame-retardants,surfactants, blowing agents, catalysts, emulsifiers/solubilizers,fillers, fungicides, anti-static substances, and mixtures of two or morethereof.

A-Side Stream

In one or more embodiments, the A-side stream may only contain theisocyanate-containing compound. In one or more embodiments, multipleisocyanate-containing compounds may be included in the A-side. In otherembodiments, the A-side stream may also contain other constituents suchas, but not limited to, flame-retardants, surfactants, blowing agentsand other non-isocyanate-reactive components. In one or moreembodiments, the complementary constituents added to the A-side arenon-isocyanate reactive.

Suitable isocyanate-containing compounds useful for the manufacture ofpolyisocyanurate construction board are generally known in the art andembodiments of this invention are not limited by the selection of anyparticular isocyanate-containing compound. Useful isocyanate-containingcompounds include polyisocyanates. Useful polyisocyanates includearomatic polyisocyanates such as diphenyl methane diisocyanate in theform of its 2,4′-, 2,2′-, and 4,4′-isomers and mixtures thereof. Themixtures of diphenyl methane diisocyanates (MDI) and oligomers thereofmay be referred to as “crude” or polymeric MDI, and thesepolyisocyanates may have an isocyanate functionality of greater than 2.Other examples include toluene diisocyanate in the form of its 2,4′ and2,6′-isomers and mixtures thereof, 1,5-naphthalene diisocyanate, and1,4′ diisocyanatobenzene. Exemplary polyisocyanate compounds includepolymeric Rubinate 1850 (Huntsmen Polyurethanes), polymeric LupranateM70R (BASF), and polymeric Mondur 489N (Bayer).

B-Side Stream

In one or more embodiments, the B-side stream may only include theisocyanate-reactive compound. In one or more embodiments, multipleisocyanate-reactive compounds may be included in the B-side. In otherembodiments, the B-side stream may also contain other constituents suchas, but not limited to, flame-retardants, surfactants, blowing agentsand other non-isocyanate-containing components. In particularembodiments, the B-side includes an isocyanate reactive compound and ablowing agent. In these or other embodiments, the B-side may alsoinclude flame retardants, catalysts, emulsifiers/solubilizers,surfactants, fillers, fungicides, anti-static substances, water andother ingredients that are conventional in the art.

An exemplary isocyanate-reactive compound is a polyol. The term polyol,or polyol compound, includes diols, polyols, and glycols, which maycontain water as generally known in the art. Primary and secondaryamines are suitable, as are polyether polyols and polyester polyols.Useful polyester polyols include phthalic anhydride based PS-2352(Stepen), phthalic anhydride based polyol PS-2412 (Stepen), teraphthalicbased polyol 3522 (Kosa), and a blended polyol TR 564 (Oxid). Usefulpolyether polyols include those based on sucrose, glycerin, and toluenediamine. Examples of glycols include diethylene glycol, dipropyleneglycol, and ethylene glycol. Suitable primary and secondary aminesinclude, without limitation, ethylene diamine, and diethanolamine. Inone or more embodiments, a polyester polyol is employed. In one or moreembodiments, the present invention may be practiced in the appreciableabsence of any polyether polyol. In certain embodiments, the ingredientsare devoid of polyether polyols.

Catalysts

Catalysts, which are believed to initiate the polymerization reactionbetween the isocyanate and the polyol, as well as a trimerizationreaction between free isocyanate groups when polyisocyanurate foam isdesired, may be employed. While some catalysts expedite both reactions,two or more catalysts may be employed to achieve both reactions. Usefulcatalysts include salts of alkali metals and carboxylic acids orphenols, such as, for example potassium octoate; mononuclear orpolynuclear Mannich bases of condensable phenols, oxo-compounds, andsecondary amines, which are optionally substituted with alkyl groups,aryl groups, or aralkyl groups; tertiary amines, such aspentamethyldiethylene triamine (PMDETA), 2,4,6-tris[(dimethylamino)methyl]phenol, triethyl amine, tributyl amine, N-methylmorpholine, and N-ethyl morpholine; basic nitrogen compounds, such astetra alkyl ammonium hydroxides, alkali metal hydroxides, alkali metalphenolates, and alkali metal acholates; and organic metal compounds,such as tin(II)-salts of carboxylic acids, tin(IV)-compounds, and organolead compounds, such as lead naphthenate and lead octoate.

Surfactants, Emulsifiers and Solubilizers

Surfactants, emulsifiers, and/or solubilizers may also be employed inthe production of polyurethane and polyisocyanurate foams in order toincrease the compatibility of the blowing agents with the isocyanate andpolyol components. Surfactants may serve two purposes. First, they mayhelp to emulsify/solubilize all the components so that they reactcompletely. Second, they may promote cell nucleation and cellstabilization.

Exemplary surfactants include silicone co-polymers or organic polymersbonded to a silicone polymer. Although surfactants can serve bothfunctions, it may also be useful to ensure emulsification/solubilizationby using enough emulsifiers/solubilizers to maintainemulsification/solubilization and a minimal amount of the surfactant toobtain good cell nucleation and cell stabilization. Examples ofsurfactants include Pelron surfactant 9920, Goldschmidt surfactantB8522, and GE 6912. U.S. Pat. Nos. 5,686,499 and 5,837,742 areincorporated herein by reference to show various useful surfactants.

Suitable emulsifiers/solubilizers include DABCO Ketene 20AS (AirProducts), and Tergitol NP-9 (nonylphenol+9 moles ethylene oxide).

Flame Retardants

Flame Retardants may be used in the production of polyurethane andpolyisocyanurate foams, especially when the foams contain flammableblowing agents such as pentane isomers. Useful flame retardants includetri(monochloropropyl) phosphate (a.k.a. tris (cloro-propyl) phosphate),tri-2-chloroethyl phosphate (a.k.a tris(chloro-ethyl) phosphate),phosphonic acid, methyl ester, dimethyl ester, and diethyl ester. U.S.Pat. No. 5,182,309 is incorporated herein by reference to show usefulblowing agents.

Blowing Agents

Useful blowing agents include isopentane, n-pentane, cyclopentane,alkanes, (cyclo) alkanes, hydrofluorocarbons, hydrochlorofluorocarbons,fluorocarbons, fluorinated ethers, alkenes, alkynes, carbon dioxide,hydrofluoroolefins (HFOs) and noble gases.

Amount of Reactants

An isocyanurate is a trimeric reaction product of three isocyanatesforming a six-membered ring. The ratio of the equivalence of NCO groups(provided by the isocyanate-containing compound or A-side) toisocyanate-reactive groups (provided by the isocyanate-containingcompound or B side) may be referred to as the index or ISO index. Whenthe NCO equivalence to the isocyanate-reactive group equivalence isequal, then the index is 1.00, which is referred to as an index of 100,and the mixture is said to be stoiciometrically equal. As the ratio ofNCO equivalence to isocyanate-reactive groups equivalence increases, theindex increases. Above an index of about 150, the material is generallyknown as a polyisocyanurate foam, even though there are still manypolyurethane linkages that may not be trimerized. When the index isbelow about 150, the foam is generally known as a polyurethane foam eventhough there may be some isocyanurate linkages. For purposes of thisspecification, reference to polyisocyanurate and polyurethane will beused interchangeably unless a specific ISO index is referenced.

In one or more embodiments, the concentration of theisocyanate-containing compound to the isocyanate-reactive compoundswithin the respective A-side and B-side streams is adjusted to providethe foam product with an ISO index of at least 150, in other embodimentsat least 170, in other embodiments at least 190, in other embodiments atleast 210, in other embodiments at least 220, and in other embodimentsat least 250. In these or other embodiments, the concentration of theisocyanate-containing compound to the isocyanate-reactive compoundswithin the respective A-side and B-side streams is adjusted to providethe foam product with an ISO index of at most 400, in other embodimentsat most 350, and in other embodiments at most 300. In one or moreembodiments, the concentration of the isocyanate-containing compound tothe isocyanate-reactive compounds within the respective A-side andB-side streams is adjusted to provide the foam product with an ISO indexof from about 150 to about 400, in other embodiments from about 170 toabout 350, and in other embodiments from about 190 to about 330, and inother embodiments from about 220 to about 280.

In one or more embodiments, where an alkane blowing agent is employed,the amount of alkane blowing agent (e.g., pentanes) used in themanufacture of polyisocyanurate foam construction board according to thepresent invention may be described with reference to the amount ofisocyanate-reactive compound employed (e.g. polyol). For example, in oneor more embodiments, at least 12, in other embodiments at least 14, andin other embodiments at least 18 parts by weight alkane blowing agentper 100 parts by weight of polyol may be used. In these or otherembodiments, at most 40, in other embodiments at most 36, and in otherembodiments at most 33 parts by weight alkane blowing agent per 100parts by weight of polyol may be used. In one or more embodiments, fromabout 12 to about 40, in other embodiments from about 14 to about 36,and in other embodiments from about 18 to about 33 of alkane blowingagent per 100 parts by weight of polyol may be used.

In one or more embodiments, where an hydrofluoroolefin blowing agent isemployed, the amount of hydrofluoroolefin blowing agent used in themanufacture of polyisocyanurate foam construction board according to thepresent invention may be described with reference to the amount ofisocyanate-reactive compound employed (e.g. polyol). For example, in oneor more embodiments, at least 15, in other embodiments at least 18, andin other embodiments at least 20 parts by weight hydrofluoroolefinblowing agent per 100 parts by weight of polyol may be used. In these orother embodiments, at most 50, in other embodiments at most 45, and inother embodiments at most 40 parts by weight hydrofluoroolefin blowingagent per 100 parts by weight of polyol may be used. In one or moreembodiments, from about 15 to about 50, in other embodiments from about18 to about 45, and in other embodiments from about 20 to about 40 ofhydrofluoroolefin blowing agent per 100 parts by weight of polyol may beused.

In one or more embodiments, the amount of surfactant (e.g., siliconecopolymer) used in the manufacture of polyisocyanurate foam constructionboard according to the present invention may be described with referenceto the amount of isocyanate-reactive compound employed (e.g. polyol).For example, in one or more embodiments, at least 1.0, in otherembodiments at least 1.5, and in other embodiments at least 2.0 parts byweight surfactant per 100 parts by weight of polyol may be used. Inthese or other embodiments, at most 5.0, in other embodiments at most4.0, and in other embodiments at most 3.0 parts by weight surfactant per100 parts by weight of polyol may be used. In one or more embodiments,from about 1.0 to about 5.0, in other embodiments from about 1.5 toabout 4.0, and in other embodiments from about 2.0 to about 3.0 ofsurfactant per 100 parts by weight of polyol may be used.

In one or more embodiments, the amount of flame retardant (e.g., liquidphosphates) used in the manufacture of polyisocyanurate foamconstruction board according to the present invention may be describedwith reference to the amount of isocyanate-reactive compound employed(e.g. polyol). For example, in one or more embodiments, at least 5, inother embodiments at least 10, and in other embodiments at least 12parts by weight flame retardant per 100 parts by weight of polyol may beused. In these or other embodiments, at most 30, in other embodiments atmost 25, and in other embodiments at most 20 parts by weight flameretardant per 100 parts by weight of polyol may be used. In one or moreembodiments, from about 5 to about 30, in other embodiments from about10 to about 25, and in other embodiments from about 12 to about 20 offlame retardant per 100 parts by weight of polyol may be used.

In one or more embodiments, the amount of catalyst (s) employed inpractice of the present invention can be readily determined by theskilled person without undue experimentation or calculation. Indeed, theskilled person is aware of the various process parameters that willimpact the amount of desired catalyst. Also, the amount of catalystemployed can be varied to achieve various desired properties such as thedesired index.

Characteristics of Foam Encasement

As indicated above, the foam produced by one or more embodiments of thepresent invention, which foam is employed to encase the fragileinsulation materials, includes a polyurethane and/or polyisocyanuratefoam. As is generally understood in the art, a foam is a cellularstructure that may include an interconnected network of solid struts orplates that form the edges and faces of cells. These cellular structuresmay, in one or more embodiments, also be defined by a “relative density”that is less than 0.8, in other embodiments less than 0.5, and in otherembodiments less than 0.3. As those skilled in the art will appreciate,“relative density” refers to the density of the cellular materialdivided by that of the solid from which the cell walls are made. As therelative density increases, the cell walls thicken and the pore spaceshrinks such that at some point there is a transition from a cellularstructure to one that is better defied as a solid containing isolatedpores.

In one or more embodiments, the developing foam is engineered to producea final foam structure that is characterized by a relatively lowdensity. In one or more embodiments, this foam may have a densitydefined according to ASTMC 303 that is less than 2.5 pounds per cubicfoot (12 kg/m²), in other embodiments less than 2.0 pounds per cubicfoot (9.8 kg/m²), in other embodiments less than 1.9 pounds per cubicfoot (9.3 kg/m²), and still in other embodiments less than 1.8 poundsper cubic foot (8.8 kg/m²). In one or more embodiments, foam may becharacterized by having a density that is greater than 1.50 pounds percubic foot (7.32 kg/m²) and optionally greater than 1.55 pounds percubic foot (7.57 kg/m²).

In other embodiments, the developing foam is engineered to produce afinal foam product having a relatively high density. In one or moreembodiments, the foam has a density, as defined by ASTM C303, of greaterthan 2.5 pounds per cubic foot (12.2 kg/m²), as determined according toASTM C303, in other embodiments the density is greater than 2.8 poundsper cubic foot (13.7 kg/m²), in other embodiments greater than 3.0pounds per cubic foot (14.6 kg/m²), and still in other embodimentsgreater than 3.5 pounds per cubic foot (17.1 kg/m²). In one or moreembodiments, the density may be less than 20 pounds per cubic foot (97.6kg/m²), in other embodiments less than 10 pounds per cubic foot (48.8kg/m²), in other embodiments less than 6 pounds per cubic foot (29.3kg/m²), in other embodiments less than 5.9 pounds per cubic foot (28.8kg/m²), in other embodiments less than 5.8 pounds per cubic foot (28.3kg/m²), in other embodiments less than 5.7 pounds per cubic foot (27.8kg/m²), in other embodiments less than 5.6 pounds per cubic foot (27.3kg/m²), and still in other embodiments less than 5.5 pounds per cubicfoot (26.9 kg/m²).

In one or more embodiments, the developing foam is engineered to providea final foam product having a desired ISO index. As the skilled personunderstands, ISO index correlates to PIR/PUR ratio and can determined byIR spectroscopy using standard foams of known index (note that ratio of3 PIR/PUR provides an ISO Index of 300), of at least 150, in otherembodiments at least 180, in other embodiments at least 200, in otherembodiments at least 220, in other embodiments at least 240, in otherembodiments at least 260, 270, in other embodiments at least 285, inother embodiments at least 300, in other embodiments at least 315, andin other embodiments at least 325. In these or other embodiments, thefoam may be characterized by an ISO index of less than 350, in otherembodiments less than 300, in other embodiments less than 275, in otherembodiments less than 250, in other embodiments less than 225, and inother embodiments less than 200.

Method of Encapsulation—First Embodiment

In one embodiment, the process of encapsulating a fragile insulationmaterial includes providing a preformed construction board, positioningone or more fragile insulation materials on the board, and depositing adeveloping foam over the fragile insulation material to at leastpartially cover the fragile insulation material and at least partiallymate the developing foam with the construction board.

Practice of one or more of these embodiments is not necessarily limitedby the type of construction board employed. In one or more embodiments,the construction board is a generally solid material such as wood,particle, or fiber board. In one or more embodiments, the constructionboard is a wood board such as plywood, luan board, or oriented-strandboard (OSB). In other embodiments, the construction board is a particleor fiber board such as masonite board, wall board, gypsum board, andvariations thereof such as those boards available under the tradenameDensDeck.

In other embodiments, construction board is or includes a polymericmaterials. In one or more embodiments, the polymeric material isgenerally solid, which refers to a structure wherein the relativedensity is greater than 0.8, in other embodiments greater than 0.85, inother embodiments greater than 0.90, and in other embodiments greaterthan 0.95. In other embodiments, the polymeric material is cellular innature, which refers to a material having a relatively density that isless than 0.8, in other embodiments less than 0.5, and in otherembodiments less than 0.3. As those skilled in the art will appreciate,“relative density” refers to the density of the cellular materialdivided by that of the solid from which the cell walls are made. As therelative density increases, the cell walls thicken and the pore spaceshrinks such that at some point there is a transition from a cellularstructure to one that is better defied as a solid containing isolatedpores.

In one or more embodiments, the construction board is a relativelylow-density polyurethane or polyisocyanurate foam board. As thoseskilled in the art appreciate, these foam boards may be generallycharacterized by a density as defined by ASTM C303 that is less than 2.5pounds per cubic foot (12 kg/m²), in other embodiments less than 2.0pounds per cubic foot (9.8 kg/m²), in other embodiments less than 1.9pounds per cubic foot (9.3 kg/m²), and still in other embodiments lessthan 1.8 pounds per cubic foot (8.8 kg/m²). In one or more embodiments,the density is greater than 1.50 pounds per cubic foot (7.32 kg/m²) andoptionally greater than 1.55 pounds per cubic foot (7.57 kg/m²).

In one or more embodiments, the construction board is a relativelyhigh-density polyurethane or polyisocyanurate foam board. In one or moreembodiments, these foam boards may be generally characterized by adensity as defined by ASTM C300 that is greater than pounds per cubicfoot (12.2 kg/m²), as determined according to ASTM C303, in otherembodiments the density is greater than 2.8 pounds per cubic foot (13.7kg/m²), in other embodiments greater than 3.0 pounds per cubic foot(14.6 kg/m²), and still in other embodiments greater than 3.5 pounds percubic foot (17.1 kg/m²). In one or more embodiments, the density of body11 may be less than 20 pounds per cubic foot (97.6 kg/m²), in otherembodiments less than 10 pounds per cubic foot (48.8 kg/m²), in otherembodiments less than 6 pounds per cubic foot (29.3 kg/m²), in otherembodiments less than 5.9 pounds per cubic foot (28.8 kg/m²), in otherembodiments less than 5.8 pounds per cubic foot (28.3 kg/m²), in otherembodiments less than 5.7 pounds per cubic foot (27.8 kg/m²), in otherembodiments less than 5.6 pounds per cubic foot (27.3 kg/m²), and stillin other embodiments less than 5.5 pounds per cubic foot (26.9 kg/m²).

Regardless of density, the polyurethane or polyisocyanurate foam boardsmay be characterized by a thickness greater than 0.255 inches (0.65 cm),in other embodiments greater than 0.30 inches (0.76 cm), in otherembodiments greater than 0.375 inches (0.95 cm), and in otherembodiments greater than 0.40 inches (1.01 cm). In these or otherembodiments, the thickness 20 may be from about 0.375 to 4.0 inches(0.95-10.16 cm) or in other embodiments from about 0.38 to 2.0 inches(0.97-5.08 cm) in thickness.

The process of these embodiments can be described with reference to FIG.1, which shows continuous process 11 employing conveyor system 13. In afirst step 15 of process 11, a construction board 17 is placed onconveyor system 13. Following this step 15, fragile insulation materials19 are deposited on or applied to construction board 17 within secondstep 21. In one or more embodiments, fragile insulation materials 19 areadhesively mated or otherwise affixed to a top planar surface ofconstruction board 17 through the use of an adhesive. Accordingly, theprocess may include the step of applying an adhesive to the fragileinsulation material, to the construction board, or to both the fragileinsulation material and the construction board. The adhesive mayinclude, for example, hot melt adhesives, contact adhesives, or liquidadhesives. As generally shown in FIG. 1, and as more specifically shownin FIG. 2, fragile insulation materials 19, which may have a rectangularor square shape, are placed on an upper surface 18 of construction board17 according to a desired pattern that provides interstices 20 betweenthe respective fragile insulation materials 19. Additionally, fragileinsulation materials 19 are placed upon upper surface 18 of constructionboard 17 in a manner that provides a gap 22 between the edge 23 ofconstruction board 17 and the outer most edge 24 of fragile insulationmaterials 19.

In one or more embodiments, an assembly of fragile insulation materialsmay be fabricated in advance of the encapsulating procedures. This mayfacilitate placement of the fragile insulation materials in to a desiredpattern. For example, in one or more embodiments, the fragile insulationmaterials may be adhered to a common substrate in a desired patternprior to incorporation of the fragile insulation materials in to theprocedures described herein. Various substrates may be used includingwoven fabrics that allow the developing foam to move therethrough.Within these embodiments, the fragile insulation materials may beadhered in a desired pattern to the fabric substrate, and then thisassembly of fragile insulation materials can be employed in practicingthe present invention.

In one or more embodiments, the fragile insulation materials may beadhered to the construction board in advance of the encapsulatingprocedures. For example, in one or more embodiments, the fragileinsulation materials may be adhered to a construction board in a desiredpattern prior to incorporation of the fragile insulation materials intothe procedures described herein. Thus, while the embodiments describedabove position the fragile insulation materials onto the constructionboard within a continuous, integrated process, other embodiments allowfor the fragile insulation materials to be positioned on theconstruction board within an “off-line” step that is separate anddistinct from the process of depositing the foam. Various adhesives maybe employed including, but not limited to, hot melt adhesives, contactadhesives, and liquid adhesives.

In one or more embodiments, the fragile insulation materials arearranged in a pattern to achieve relatively high coverage with respectto the planar surface of the finished foam composite. In one or moreembodiments, the fragile insulation materials are arranged in a patternsufficient to cover at least 60%, in other embodiments at least 70%, inother embodiments at least 75%, and in other embodiments at least 80% ofthe surface area of the final foam composite, where the surface area istaken on a plane of the final product that passes through the insulatingmaterials. In one or more embodiments, while increased coverage isdesirable, the pattern may desirably provide for sufficient intersticesbetween the respective fragile insulation materials. Also, the patternmay desirably provide for sufficient gaps between the outer most fragileinsulation materials and the edges of the composite board. Theseinterstices and gaps will, once filled with the foam material, providesufficient integrity to the composite board including sufficientmechanical strength between the planar faces of the board.

Following placement of the fragile insulation materials 19 on the uppersurface 18 of board 17, developing foam 25 is deposited over the uppersurface 26 of fragile insulation materials 19, as well as withininterstices 20 and gap(s) 22 exposed in the upper surface 18 ofconstruction board 17.

As described above, the developing foam 25 can be provided from anA-side stream of reactants 27 and a B-side stream of reactants 29. Usingconventional procedures, the developing foam can be deposited using oneor more mix heads, not shown.

In one or more embodiments, sufficient developing foam 25 is depositedover the upper surface 26 of fragile insulation materials 19 to providea layer of sufficient thickness to protect the fragile insulationmaterials. In one or more embodiments, this layer may be from about 0.25inches (0.64 cm) to about 2 inches (5.08 cm), in other embodiments fromabout 0.375 inches (0.95 cm) to about 1 inch (2.54 cm), and in otherembodiments from about 0.5 inches (1.27 cm) to about 0.75 inches (1.91cm).

Following the step of depositing foam, a facer material 31 may beapplied to the developing foam 25 in a facer application step 33 ofprocess 11. Following application of facer 31, the pre-cured composite34 can then be conveyed into a laminator 23, which sets the overallthickness of the finished composite 35 and wherein at least partialcuring of the foam takes place. For example, within laminator 23, heatmay be applied from heat source 37 to facilitate the polyurethane and/orpolyisocyanurate reaction and thereby cure the polyurethane and/orpolyisocyanurate material in the formation of the cellular foam product.In one or more embodiments, the surface of the composite is heated toachieve a surface temperature of from about 140 to about 180° C.

As with conventional procedures for producing polyisocyanurateconstruction boards, once the polyisocyanurate material leaves thelaminator, the foam product (which may be referred to as a composite)can be trimmed or otherwise finished, and cut to length. In practicingthe present invention, the foam product can be cut to length and, incertain embodiments, the fragile insulation material will not be cut. Inother words, in one or more embodiments, the foam product will be cut tolength by cutting between the interstices that may be provided betweenthe fragile insulation materials. Several techniques can be employed todetermine the location of the interstices, which may not be readilyapparent due to the fact that they are encapsulated. In one or moreembodiments, x-ray or other analytical techniques can be employed tolocate the interstices between the fragile insulation materials. Inother embodiments, the fragile insulation materials can be modified witha place marker prior to being incorporated into the process. Forexample, a vertically extending marker can indicate one or more edges ofthe fragile insulation materials, and these markers can be later used toidentify the interstices and thereby provide a location for cutting thefoam product to length.

Method of Encapsulation—Second Embodiment

In a second embodiment of the present invention, a process ofencapsulating a fragile insulation material includes depositing adeveloping foam on to a facer material, positioning one or more fragileinsulation materials onto the developing foam, and subsequentlydepositing additional developing foam over the fragile insulationmaterial to at least partially cover the fragile insulation material andmate with the previously deposited developing foam.

The process of one or more of these embodiments can be described withreference to FIG. 3, which shows continuous process 61 employingconveyer system 63. In a first step 65 of process 61, a facer 67 ispositioned on conveyor 63. In a first foam depositing step 69, adeveloping foam 70 is deposited on facer 67 carried by conveyor 63. Aswith conventional procedures, layer 75 of developing foam 70 is providedby mixing an A-side stream of reactants 72 and a B-side stream ofreactants 74. By depositing developing foam 70 on to a surface of facer67, a layer 75 of developing foam 70 is formed on facer 67. In a secondstep 77, fragile insulation material(s) are positioned on developingfoam 70. As with other embodiments of this invention, fragile insulationmaterials 79 are positioned on layer 75 of developing foam 70 in adesired pattern. With reference again to FIG. 2, the pattern may includeinterstices 20 between the respective fragile insulation materials 79(referred to as 19 in FIG. 2). Likewise, the pattern may provide forgaps between the edge of the conveyor and the edge(s) of the outmostfragile insulation materials.

Prior to placing fragile insulation materials 79 onto layer 75 ofdeveloping foam 70, the process may include a step 80 for depositing oneor more spacers 81 onto facer 67. The placement of spacers 81 onto facer67 can take place before application of the developing foam 70 to facer67, or in other embodiments the application of spacers 81 to facer 67can take place after developing foam 70 is applied to facer 67. In anyevent, spacer(s) 81 provide a support upon which the fragile insulationmaterials 79 may be positioned and thereby provide sufficient spacingbetween facer 67 and fragile insulation materials 79.

In one or more embodiments, the operation of spacer(s) 81 can be betterdescribed with reference to FIG. 4. As shown, spacers 81 are proximateto facer 67 and provide a support for fragile insulation materials 79 sothat a sufficient space 83 exists between facer 67 and fragileinsulation materials 79. In one or more embodiments, space 83 may befrom about 0.25 inches (0.64 cm) to about 2 inches (5.08 cm), in otherembodiments from about 0.375 inches (0.95 cm) to about 1 inch (2.54 cm),and in other embodiments from about 0.4 inches (1.02 cm) to about 0.75inches (1.91 cm).

Practice of one or more embodiments of the present invention is notnecessarily limited by the shape of the spacer. For example, the spacermay take on the form of a jack, which generally has six points or knobsprojecting from a common base. Likewise, the material from which thespacer is fabricated can vary. For example, in one or more embodiments,the spacer may be fabricated from a plastic material or a thermosettingmaterial. In one or more embodiments, spacers 81 may be adhesivelysecured to facer 67. In other embodiments, spacers 81 may be adhesivelysecured to fragile insulation materials 79. In one or more embodiments,spacers 81 may be adhesively secured to both facer 67 and fragileinsulation materials 79.

In one or more embodiments, the spacer may include a fabric. Thesefabrics may have sufficient thickness to provide a desired gap betweenfacer 67 and the positioning of fragile insulation materials 79. Thisgap may be consistent with the dimensions provided above for spacers 81.While the fabric will have sufficient density, and therefore sufficientcompressive strength, to maintain the fragile insulation materialssufficiently above facer 67 to maintain the desired gap between thefacer and the fragile insulation materials, the fabric is characterizedby a density that allows for the adsorption of developing foam, andthereby allows the developing foam to fully encapsulate the fragileinsulation materials. This step of applying the developing foam will bedescribed in greater detail herein below.

In one or more embodiments, the spacer may be pre-attached to the facermaterial, in other embodiments pre-attached to the fragile insulationmaterial, or in other embodiments to both the facer material and thefragile insulation material prior to incorporating these elements of theprocess of the present invention. For example, in one or moreembodiments, the spacer is pre-attached to the fragile insulationmaterial within an “off-line” step that is separate and distinct fromthe process of depositing the developing foam onto the fragileinsulation material.

As indicated above, whether or not spacers are employed, the step 77 ofpositioning fragile insulation materials 79 onto layer 75 of developingfoam 70 creates a desired pattern having interstices between the variousfragile insulation materials 79, as well as a gap between the outer mostedge of the outer most fragile insulation materials 79 and the edge ofconveyor 63, which may be in the form of a trough. Once fragileinsulation materials 79 are positioned on developing foam 70, a secondapplication 85 of developing foam 87 is applied to at least partiallycover fragile insulation materials 79 positioned over developing foam70. The second step of depositing developing foam 85 may occur accordingto conventional procedures wherein an A-sides stream of reactants ismixed with a B-side stream of reactants within an appropriate mix head.Second step 85 of depositing a developing foam 87 creates a second layer89 of developing foam that at least partially covers fragile insulationmaterials 79 and at least partially mates with first layer 75 ofdeveloping foam 70 to thereby encapsulate fragile insulation materials79 within polyisocyanurate foam. In one or more embodiments, it may bedesirable to position the mix heads to deposit foam within theinterstices between the respective fragile insulation materials or nearthe edges of the facer.

Following second application 85 of developing foam 87, a second facermaterial 91 can be mated with top surface 92 of second developing foamlayer 89 to form a composite structure having opposing facers 67 and 91.As with the previous embodiments, the pre-cured composite can be placedinto a laminator and heated (e.g., heating step 99). The finishedcomposite can be cut to length and/or otherwise finished.

Method of Encapsulation—Third Embodiment

In a third embodiment, the process of encapsulating a fragile insulationmaterial includes positioning one or more spacers on a facer material,subsequently positioning one or more fragile insulation materials ontothe spacers, and subsequently depositing a developing foam onto thefragile insulation materials and the facer.

The process of one or more of these embodiments can be described withreference to FIG. 5, which shows continuous process 101. Continuousprocess 101 employs conveyor system 103. In a first step 105, facermaterial 107 is positioned on an upper surface of conveyor 103.

In a subsequent step 110, spacers 109 are positioned on an upper surface108 of facer 107. These spacers may be similar or the same as thosespacers described above with respect to other embodiments. For example,and as indicated above, the spacers may include a plurality of devicessuch as jacks or plugs. Alternatively, the spacer may include a fabrichaving sufficient thickness to provide a desired gap between the facerand the fragile insulation material. Also, as indicated above, thespacer may be affixed or otherwise adhered to the fragile insulationmaterial, to the facer, or to both the facer and the fragile insulationmaterial. In one or more embodiments, the spacer is adhered or otherwiseaffixed by providing an adhesive as part of an “on-line” step integratedwith other steps of the process. In other embodiments, the spacer may bepre-adhered or pre-affixed to the facer, to the fragile insulationmaterial, or to both the facer and the fragile insulation material in an“off-line” step that is separate and distinct from the step ofdepositing the developing foam.

Following application of spacers 109, the next step 111 includespositioning fragile insulation materials 113 in a desired pattern overspacers 109. As with previous embodiments, the spacers serve to create agap 115 between upper surface 108 of facer material 107 and a lowersurface 114 of fragile insulation material 113. Also, the pattern inwhich fragile insulation materials 113 are positioned over spacers 109may, as with previous embodiments, provides interstices between thevarious fragile insulation materials 113, as well as a gap between theoutermost edge of the outer most fragile insulation materials 113 andthe edge of conveyor 103, which may be in the form of a trough.

Once the fragile insulation materials 113 are positioned over spacers109, a subsequent step 117 includes depositing a developing foam 119onto fragile insulation materials 113 and facer 107. As with theprevious embodiments, this developing foam 119 can be provided by themixture of an A-side stream of reactants 121 and a B-side stream ofreactants 123. This step 117 of depositing foam 119 encapsulates fragileinsulation materials 113 through the mobility of developing foam 119. Inother words, developing foam 119 has sufficient fluidity to contactfacer 107 by passing through the interstices that exist between thevarious fragile insulation materials 113 and the gaps that exist betweenthe outer edges of the fragile insulation materials and the edges of theconveyor 103.

In one or more embodiments, the process parameters are adjusted toensure that the developing foam fully encapsulates the fragileinsulation materials. In particular, adjustments are made to ensure thatthe developing foam flows between the interstices that exist between thepanels, the gaps that exist between the edge panels and the troughwalls, and the gap that exists between the bottom of the fragileinsulation materials and the facer. For example, adjustments may need tobe made to ensure that the developing foam flows under the fragileinsulation materials. In one or more embodiments, these processparameters may include one or more of the following (i) the number ofmix heads employed, (ii) the positioning of the mix heads, and (iii) thegel time of the developing foam. In one or more embodiments, thedeveloping foam is engineered to have a gel time of at least 10 seconds,in other embodiments at least 12 seconds, in other embodiments at least14 seconds, and in other embodiments at least 16 seconds. In these orother embodiments, the developing foam is engineered to have a gel timeof less than 30 seconds, in other embodiments less than 25 seconds, andin other embodiments less than 20 seconds. As the skilled personunderstands, gel time generally refers to the time at which thedeveloping foam loses appreciable mobility. The skilled person is alsoaware of conventional tests, such as reactivity tests, that measure geltime.

As with the other embodiments, the next step of this embodiment mayinclude the placement of facer material 131 on top of the developingfoam, and placement of the pre-cured composite into the laminator (e.g.,laminator 133, which may provide heat 135). After exiting the laminator,the composite can be cut to length or otherwise finished.

Various modifications and alterations that do not depart from the scopeand spirit of this invention will become apparent to those skilled inthe art. This invention is not to be duly limited to the illustrativeembodiments set forth herein.

1-20. (canceled)
 21. A composite insulation board comprising: (i) apreformed construction board having a first planar surface and a secondplanar surface; and (ii) a plurality of insulation devices at leastpartially encapsulated by an insulating foam material, wherein theplurality of insulation devices are positioned directly on the firstplanar surface of the preformed construction board.
 22. The compositeinsulation board of claim 21, further comprising a facer positionedabove both the plurality of insulation devices and the insulating foammaterial.
 23. The composite insulation board of claim 21, wherein thepreformed construction board is a polyisocyanurate foam board.
 24. Thecomposite insulation board of claim 23, wherein the polyisocyanuratefoam board has a density of less than 2.5 pounds per cubic foot.
 25. Thecomposite insulation board of claim 23, wherein the polyisocyanuratefoam board has a density of greater than 2.5 pounds per cubic foot. 26.The composite insulation board of claim 23, wherein the polyisocyanuratefoam board has a density of greater than 3.0 pounds per cubic foot. 27.The composite insulation board of claim 21, wherein the plurality ofinsulation devices are positioned directly on the preformed constructionboard and interstices exist between the insulation devices.
 28. Thecomposite insulation board of claim 27, wherein the insulating foammaterial is positioned directly over an upper surface of the pluralityof insulation devices and in the interstices between the insulationdevices.
 29. The composite insulation board of claim 21, wherein theinsulating foam material provides a foam product with an ISO index of atleast
 190. 30. The preformed composite insulation board of claim 21,wherein the plurality of insulation devices are adhered to the preformedconstruction board.